Insert for foiled food tubs and the like

ABSTRACT

The present invention relates to a stackable packaging insert for storing and transporting articles, such as foiled food tubs. The insert is formed from a blank that can be folded into a tray-like packaging insert with individual compartments. Each compartment has a base and support tabs. Between adjacent bases, the support tabs meet at a triangular connector. When positioned within a container, the support tab ends and triangular connectors rest against the interior walls of the container. Articles within the positioned insert are suspended on the support tabs and triangular connectors.

FIELD OF THE INVENTION

This invention relates to packaging inserts and blanks for the same, and more specifically inserts for transporting and cushioning articles such as foiled food tubs.

BACKGROUND

The secure packing and transporting of articles to consumers is critical for producers and distributors of goods. Replacing and/or repairing damaged articles is a high financial burden to the responsible party. To avoid this expense, it is cost-effective to protect articles with inserts during storage and transportation. Packaging inserts support the articles during transportation to ensure that the articles arrive at their destination in proper condition. Fragile items such as bottles, vials, dishes, and packaged food tubs should usually be shipped with packaging inserts. Often, articles may simply be stacked in secondary containers without packaging inserts for storage and transportation. While packing articles without protective inserts is simple and economical, articles shipped without protective inserts are very likely to arrive damaged at their destination. Alternatively, articles may be packed in secondary containers with packing supplies, such as foam peanuts, bubble wrap, paper or tissue. However, articles packed with these packing supplies are not sufficiently compartmentalized when multiple articles are shipped in a single secondary container and are still likely to arrive at their destination damaged. Further, such packing supplies are expensive and labor intensive to handle both during packing and unpacking.

Different packaging inserts serve different purposes. Inserts may be used to economize space in the shipping container in order to increase the number of articles per shipment. Alternatively, light-weight inserts or those incorporating air cushions may be used to decrease the overall weight of each shipment. As another example, inserts may be used to improve packing and/or unpacking efficiency. As a final example, inserts may be used to provide additional support to different parts of the packed article, for example, the base of a vial, the neck of a bottle, or the corners of a dish. Additionally, packaging inserts may be made of many different types of material including paper, paperboard, corrugated board, foam, and plastics.

It is desirable in the art to devise packaging inserts that hold multiple articles wherein each article is held in an individual compartment. Some articles require individual compartments during transportation to preserve the integrity of the article. For example, foiled food tubs are best stored and transported in individual compartments to ensure that the foil tub and thin shrink wrap film sealed to the foil tub are not damaged during storage and transportation. Additionally, shrink wrap film is expensive; therefore, it is preferable to transport such tubs in protective inserts that preserve the integrity of the delicate, thin film seals rather than increasing the weight of the film. It is also desirable for such packaging inserts to be stackable within a secondary container so that more articles can be shipped per secondary container. Further, it is desirable in the art to devise packaging inserts that provide air-cushions between multiple layers of articles in stacked inserts within secondary containers. Finally, it is desirable in the art to devise packaging inserts that are simple and cost effective to both use and manufacture. Inserts that can be quickly assembled and positioned within the secondary container are very cost effective to form and pack on the production lines. Packaging inserts that can be quickly hand-folded into position without specialized equipment are further cost-effective to form and pack. Additionally, packaging inserts from a single, unitary blank are cost effective to manufacture.

The packaging inserts currently in the art do not meet these qualifications. Specifically, known inserts do not provide individual compartments for each article with corner supports around each compartment. Additionally, known inserts often consist of multiple pieces and are difficult and time-consuming to assemble and position within the secondary container. Finally, known stackable inserts do not have air-cushions between multiple layers of articles in stacked inserts within an secondary container to adequately support the packed articles.

BRIEF SUMMARY OF THE INVENTION

The present packaging insert is formed from a single, unitary blank, which is sized to fit into a secondary container. The blank can be folded into a fray-like packaging insert with individual compartments. Each insert has a two or more substantially rectangular bases. The number of bases in an insert corresponds to the number of article compartments when the insert is positioned in the secondary container. The present insert has support tabs at the corner of each base that extend outwards. Between adjacent bases, the support tabs meet at a triangular connector. When the insert is positioned within the secondary container, the ends of the support tabs fold upwards and inwards. The support tabs and triangular connectors rest against the interior wall of the container. Articles placed within the positioned insert are suspended on the support tabs and triangular connectors; this provides an air cushion between the layers of articles when multiple inserts are stacked upon each other.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a top plan view of a blank forming the insert of according to the invention.

FIG. 2 is a top perspective view of a set-up insert according to the invention.

FIG. 3 is a bottom perspective view of a set-up insert according to the invention.

FIG. 4. Is a cut-away view of a set-up insert, where the items shown in phantom lines are provided for environment only.

FIG. 5 is an exploded view of a number of inserts and articles positioned within a secondary container, where the items shown in phantom lines are provided for environment only.

FIG. 5 is an environmental view of a number of inserts and articles positioned within a secondary container, where the items shown in phantom lines are provided for environment only.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible to embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention. The present disclosure and preferred embodiments should be considered an exemplification of the principles of the invention and are not intended to limit the broad aspect of the invention.

The insert 10 is formed from a single, unitary blank B. The blank B has a plurality of substantially rectangular bases 12. The number of bases 12 in a blank B corresponds to the number of compartments 80 the insert 10 will have when the blank B is folded into position, as is best shown in FIGS. 2 and 3 and discussed below. In a preferred embodiment of the invention shown in FIG. 1, there are two bases 14 in a single column per blank B. In another embodiment of the invention (not illustrated), there are two bases 14 in two columns per blank, namely the pattern of blank B is doubled. Similarly, in yet another embodiment of the invention, there are three bases 14 in a single column per blank. The number of columns and number of bases 14 per column may be more than or less than the embodiments described. For example, in the preferred embodiment shown in FIG. 1 with two bases 14 in a single column, an insert made of double face, singlewall, B-flute corrugated board may store and transport foiled food tubs. Additional bases, layers, and alternative articles may necessitate a stronger material or allow a weaker material.

The blank B has rectangular support tabs 24 rotationally positioned at fold lines 20 of each base 14. Between adjacent bases 14, the support tabs 24 meet at a triangular connector 32. Two sides of the triangular connector 32 are connector fold lines 34 that join the triangular connector 32 to the support tabs 24 of adjacent bases 14. When the remaining side of the triangular connector 32 is along the perimeter of the insert, the side is a connector edge 36. A connector edge 36 terminates the triangular connector 32 in a flat edge. Support tabs 24, on the exterior corners of each base 14 form support end tab edges 26.

The blank B has cutouts 22 between adjacent bases 14. These cutouts 22 are preferably hexagonal as shown in FIG. 1, but other geometric forms may be used to achieve the same functionality. Two sides of a hexagonal cutout 22 are defined by adjacent sides 18 of the bases 14 and four sides of the hexagonal cutout 22 are defined by the support tab sides 28 of the support tabs 24 that connect the adjacent bases 14 via a triangular connector 32.

The blank B may be manually or hand folded to form the insert 10, as shown in FIGS. 2 and 3. Alternatively, the blank could be mechanically folded into position. The ends (support end tab edges) 26 of the support tabs 24 fold upwards and inwards along the tab fold lines 30. As the ends 26 of the support tabs 24 fold upwards and inwards, the insert 10 also folds along the connector fold lines 34. As the insert 10 folds into position, the support tabs 24 move into an intersecting plane with the bases 14, while the triangular connectors 32 remain parallel with the bases 14. In a preferred embodiment of the invention shown in FIGS. 2 and 3, the support tab ends 26 fold upwards and inwards until the support tabs 24 are angularly positioned 90 degrees upwards from the bases 14.

Referring now to FIGS. 5 and 6, each compartment 80 of the insert 10 stores one article 100. A compartment 80 is generally formed from a base 12, two exterior support tabs 24 and two internal support tabs 24. The two compartments 80 are adjacent to one another as each of the bases 12 are in or near contact with each other (as shown in FIG. 2) with triangular connectors 32 connecting the respective interior support tabs 24. When the insert 10 is positioned within the secondary container 106, the support tab ends 26 along the perimeter of the insert 10 rest angularly against the interior walls 108 of the secondary container 106. Further, the support tab ends 26 at the corners of the insert 10 rest diagonally against two interior walls 108 at an interior corner 110. The perimeter side 16 of the base 14 is positioned next to an interior wall 108 of the secondary container 106. The support tab ends 26 between adjacent bases 14 fold upwards and the adjacent sides 18 of the bases 14 move towards each other to narrow or completely close the hexagonal cutout 22. The connector edges 36 of triangular connectors 32 along the perimeter of the insert 10 rest against an interior wall 108 of the secondary container 106.

Referring now to FIGS. 2 and 4, he compartments 12 of the insert 10 are fully defined when the support tabs ends 26 and flat connector edges 36 are resting against the interior walls 108 of the secondary container 106. The article 100 should have a bottom 104, a ledge 102 around the perimeter and a diagonal diameter (P) measured across the article 100 from diagonal corners of the article. When the insert 10 is positioned within the secondary container 106, the diagonal distance (D) between the support tab ends 26 around each compartment 12 should be slightly less than the diagonal diameter (P) of the ledge 102. The depth (S) of the insert 10, measured from the bases 14 to the support tab ends 26, should be slightly greater than the article height (H), measured from the bottom 104 of the article to the ledge 102.

When the insert 10 is positioned within the secondary container 106, articles 100 may be placed within the compartments 12. The ledge 102 of the articles 100 rests on the support tab ends 26 and the triangular connectors 32 around each compartment 12. Because the depth (S) of the insert 10 in its folded position is slightly higher than the article height (H), articles stored in the positioned inserts 10 are suspended above the bases 14. In a preferred embodiment of the invention, the articles 100 are suspended 3/16^(th) inch above the bases 14. Multiple inserts 10 may be stacked upon each other. When the inserts 10 are stacked, the base 14 of the top insert 10 rests on the article 100. In the preferred embodiment of the invention described herein where the insert material is singlewall, B-flute corrugated board and the insert has two compartments in a single column for the storage and transportation of foiled food tubs, three layers of articles 100 in stacked inserts 10 may be packaged per secondary container 106. Additional compartments, alternative articles and/or alternative material may necessitate fewer layers of articles 100 or allow more layers of articles 100 per container 106.

In a preferred embodiment of the invention, the insert 10 blank B is made of corrugated board. In another embodiment, the blank is made of double face, singlewall, B-flute corrugated board. Alternatively, the corrugated board could be single face and/or doublewall, triplewall, or any other suitable construction. Additionally, the flute can be A-flute, C-flute, E-flute, F-flute, micro-flute, or any other suitable flute size. Alternatively, the blank could be made with non-corrugated board, including but not limited to paper, paperboard, foam, plastics and combinations thereof.

While particular embodiments of the invention have been illustrated and described in detail herein, it should be understood that various changes and modifications may be made in the invention without departing from the spirit and intent of the invention as defined by the appended claims. 

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 5. A protective insert for articles with a ledge and a bottom and having a height from the ledge to the bottom and a diagonal diameter across the ledge, comprising: a. a plurality of connected compartments that are substantially parallel and in the same horizontal plane with another, wherein each compartment has a base with at least one adjacent side and four corner gussets, the compartment further having support tabs at each corner gusset extending angularly upwards and outwards from the base; b. a plurality of triangular connectors joining the support tabs between adjacent sides, the triangular connectors are parallel with the bases and the insert has a depth slightly greater than the article height and distance between diagonal support tabs across the base that is slightly less than the article diagonal diameter.
 6. The protective insert of claim 5, wherein the support tabs are angularly positioned at about 90 degrees upwards from the base and the adjacent sides are adjacent to each other.
 7. The protective insert of claim 5, wherein the insert is a material selected from the group consisting of corrugated board, paper, paperboard, foam, plastics and combinations thereof.
 8. The protective insert of claim 5, wherein the insert has two bases and two triangular connectors.
 9. A method of packing articles having a bottom, a ledge and a height measured from the bottom to the ledge within a secondary container having a box floor, interior walls and corners, comprising: a. folding a packing insert, wherein the packing insert has a perimeter and a plurality of connected compartments that are substantially parallel and in the same horizontal plane with another comprising a plurality of bases and each base has four corner gussets and at least one adjacent side interior to the insert, the insert further having a plurality of support tabs where a tab extends from each corner gusset and the support tabs having a tab fold line joining the support tab to the base at the corner gusset and having an end opposite the tab fold line, and the insert further having a plurality of triangular connectors having two connector fold lines joining the triangular connector to the support tab ends between adjacent sides, wherein the support tab ends are folded upwards and inwards along the tab fold lines while the triangular connectors are folded downwards along the connector fold lines; b. positioning the insert within the secondary container, wherein the bases of the insert are pressed downwards towards the box floor, the triangular connectors around the perimeter of the insert rest on the interior walls and the support tab ends unattached to the triangular connectors diagonally rest on the corners of the container, and the insert has a depth measured from the insert bases to the support tab ends; and c. placing a plurality of articles into the insert, wherein the article ledges rest on the triangular connectors and support tab ends around each base.
 10. The method of claim 9, further comprising repeating the first, second, and third step.
 11. The method of claim 10, further comprising repeating the first, second, and third step three times. 